Throttle sticking/binding

[SS109]

While test riding my buddies MR Pro the throttle stuck wide open. It was the only time on this ride that I went 100% full throttle. It scared the hell out of me for a second but luckily I handled it and didn't end up crashing. I think I caught it on video as well.

Anyone have, or have heard of anyone, having problems with the throttle cable on the '18+ bikes? I couldn't get the desired free play on the throttle even after adjusting both adjusters fully in. It seems the cable is just a tad too short, IMO, and maybe that pulled the slide up so far that it hung up just a bit. I know it isn't the throttle tube assembly that's the problem.

I really want to find the cause of this as I don't want my buddy, nor his bike, to get hurt.

 

[(F5)]

I run motion pro as cable end adjuster fixed. Or safely wire both ends so they can't jump out and hang up.

Very scary. But I'd offer another possibility.
Dirt scratched the needle. That can damage the needle jet. I've had it happen and it kills needle twice and almost me. Pull clutch and who cares has to be attitude.
Had to fit needle jet tower to fix damage. Tiny Scratches on needle will be the Tell.

 

[Anders]

I run motion pro as cable end adjuster fixed. Or safely wire both ends so they can't jump out and hang up.

I also use the MotionPro cable.

 

[gasgasman]

Thread 'Motion Pro T3 throttle cable'

Feb 10, 2012

My OEM throttle cable leaves a lot to be desired. I never could get the right amount of free play adjusted.

I took a chance and ordered a Motion Pro T3 Slidelight throttle cable for a KTM 2 stroke.
The Motion Pro cable has a built in pivot to adjust the cable and "captured" ends. They WON"T pull out of either end. No safety wire need at all.

The KTM throttle cable fitted right up 100%. The cable could be an inch shorter, but will work well for riders with tall bars.
The cable are very high quality and has some sturdy cover sleeves in the high wear areas. Action is very smooth.

The cable...

• gasgasman
• Replies: 49
• Forum: Enduro Product Reviews

 

[SS109]

Ok, carb looks perfect even under a magnifying glass and cable feels smooth. Of course, I kind of expected this as the bike only had 30 minutes of run time when I took it on the ride. It was literally a brand new bike. Still don't see what caused the issue so I'm ordering the new cable and hopefully, once installed, this problem won't ever come up again.

 

[Moto7man]

See below for throttle cable information. Just like SS109, on my Ranger I could not get the free play on my Ranger carb. I even had it stick wide on the stand once. It didn’t matter how I routed it. When I mounted my ohlins damper it was worse. I didn’t want to slam $64.00 into another cable so I looked to see if there were all alternatives.

It seems the Honda throttle cables as listed below will work, see the specific lengths. I went one step further and found a Chinese cable on Amazon which listed the longest Honda part number. I ordered the 17910-KZ3-B00 copy, it was $9.29 including shipping. When I received it the adjuster was a little different looking but it screwed right into the Ranger throttle and the cable entering the carb end did not have a bend in it.
Otherwise, it is working just fine, the cable is smooth and the adjuster has enough free play. I will post updates. If I have trouble I will try to go with a Honda oem cable but for now it seems fine. See credit below from Garyjp4 on KTM Talk.


Research and credit goes to Garyjp4 on KMtalk


I ordered the 97-99


Throttle Cables (Longer then stock KTM @)


Cable Sealing Cap (Honda CR250R) 16148-KB1-921 (Personally I like the boot from the throttle end of the old cable used at the carb ().


1993-96 CR250R cable = 2.8" longer than stock KTM Honda C P/N 17910-MAC-670


1997-99 CR250R cable = 4.3" longer than stock KTM Honda P/N 17910-KZ3-B00


2000 CR250R cable = 4.9" longer than stock KTM Honda P/N 17910-KZ3-J20

 

[Hellcat]

Maybe cable is routed wrong . Years ago I had an issue like this on my xc200 . But twice when it did it was in tight woods and crashed both times violently . I made a thin piece of steel and drilled holes in it . One end went under screw adjuster on top of carb and cable was routed thru it. .this pinched and held cable from coming out . That was not the issue though. .it was a tiny clear piece of sand / rock that would get sucked up into main jet sometimes and cause needle to not go back down ! One tiny piece of sand almost killed me twice !

 

[Moto7man]

Yikes, that sounds wild.

 

[SS109]

Man, I never updated this? My apologies.

I installed the Motion Pro T3 cable #10-3000 and everything has been perfect since.

As for improper cable routing, no, that wasn't the problem. It was routed the way the manual says it should be and where I had it stick open was on a nearly straight section so no turning to help bind it or hang it open. Here is the video of it starting right before it happened.

 

[Moto7man]

Yikes, that sounds wild.